KUHN VBP 2160 User manual

Original instructions
ZNA082GB B
OPERATOR'S MANUAL
Baler / wrapper combination
VGRW000732 >..../ VGRV000478 >....
VBP2160 - VBP2190
ZNA082GB B
- English - 09-2013

Dear Owner
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$Dear Owner
You have purchased a KUHN machine. Into it have gone years of thought, research and improvement. You will
find, as have thousands of owners all over the world, that you have the best that engineering skill and actual
field testing can produce. You have purchased a dependable machine, but only through proper care and
operation can you expect to receive the performance and long service built into it.
This manual contains all the necessary information for you to receive full efficiency from your machine. The
performance you get from this machine is largely dependent on how well you read and understand this manual
and apply this knowledge. Please DO NOT ASSUME YOU KNOW HOW TO OPERATE AND MAINTAIN YOUR
MACHINE before reading this manual carefully. KEEP THIS MANUAL AVAILABLE FOR REFERENCE. Pass
it on to the next owner if you re-sell the machine.
Your KUHN dealer can offer a complete line of genuine KUHN service parts. These parts are manufactured and
carefully inspected in the same factory that builds the machine to assure high quality and accurate fitting of any
necessary replacements.
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About improvements
We are continually striving to improve our products. It therefore reserves the right to make improvements or
changes when it becomes practical to do so, without incurring any obligations to make changes or additions to
the equipment sold previously.
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Wear parts
Wearing parts fitted on our machines have been tested in very different situations to optimize their service life.
Nevertheless, the service life depends highly on the conditions of use (products to handle, soil, weather
conditions, etc...).
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Designated use of the machine
This machine is only designed to be used for agricultural purposes. Any use whatsoever other than the above
mentioned is not proper use. Neither the manufacturer nor the dealer is liable for any damage resulting from
improper use of the machine. The operator of the machine alone is liable in this case.
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Document illustrations
The illustrations in this manual may be based on one type of machine only. However, all instructions apply to all
machines covered in this manual.
Copyright 2013 KUHN

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Contents
$Contents
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Dear Owner.....................................................................................................................1
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Contents..........................................................................................................................2
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Delivery ...........................................................................................................................7
Check on delivery.............................................................................................................................7
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Identification of the machine.........................................................................................8
Front view..........................................................................................................................................8
Rear view...........................................................................................................................................8
Model identification plate ................................................................................................................9
Optional equipment........................................................................................................................10
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Safety.............................................................................................................................12
Description of symbols used in this document...........................................................................12
Safety instructions.........................................................................................................................13
Location and description of safety decals on the machine .......................................................26
Road safety equipment and recommendations...........................................................................34
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Machine specifications................................................................................................35
General............................................................................................................................................35
Description and glossary...............................................................................................................35
Technical specifications................................................................................................................41
Required equipment.......................................................................................................................54
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Hitching the machine...................................................................................................56
Safety...............................................................................................................................................56
General............................................................................................................................................57
Description of control elements....................................................................................................58
Manoeuvring...................................................................................................................................58
Hitching...........................................................................................................................................59

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Electrical connections...................................................................................................................64
Hydraulic connections...................................................................................................................67
Pneumatic connections.................................................................................................................73
Parking and emergency brake......................................................................................................75
Testing the machine after hitching...............................................................................................75
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Preparation for use...................................................................................................... 76
Safety ..............................................................................................................................................76
General............................................................................................................................................78
Insert the twine.............................................................................................................................102
Net roll installation.......................................................................................................................105
Scraper adjustment......................................................................................................................109
Core density adjustment .............................................................................................................110
Automatic chain lubrication system [+]..................................................................................... 111
Bale Wrapper................................................................................................................................ 111
Table adjustments........................................................................................................................112
Pre-stretcher adjustment.............................................................................................................113
Film roll installation .....................................................................................................................114
Film roll installation .....................................................................................................................114
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Instructions for transport.......................................................................................... 116
Safety ............................................................................................................................................116
General conditions.......................................................................................................................118
Machine in transport position.....................................................................................................119
Bale turner [+]...............................................................................................................................123
Wheels / tires................................................................................................................................124
Road travel check list ..................................................................................................................124
Road transport..............................................................................................................................125

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Preparations at the field ............................................................................................126
Safety.............................................................................................................................................126
Set into operating mode ..............................................................................................................127
Lower the pickup..........................................................................................................................128
Setting the crop guard.................................................................................................................129
Bale pressure................................................................................................................................130
Wrapper.........................................................................................................................................133
Baler check list.............................................................................................................................134
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Operation ....................................................................................................................135
Safety.............................................................................................................................................135
Pickup............................................................................................................................................136
Windrow dimensions ...................................................................................................................137
Swivelling the knives in and out.................................................................................................137
Bale diameter................................................................................................................................139
Mixed chamber kit [+]...................................................................................................................139
Binding type selection.................................................................................................................140
Film wrapping...............................................................................................................................143
Manual or automatic mode..........................................................................................................144
Driving...........................................................................................................................................145
Baling process..............................................................................................................................147
After the first bale.........................................................................................................................156
Re-baling bales.............................................................................................................................157
Finishing bale production............................................................................................................157
Cleaning the bale chamber..........................................................................................................158
Menus............................................................................................................................................159
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Optional equipment....................................................................................................228
General..........................................................................................................................................228
Equipment.....................................................................................................................................228

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Cleaning and care...................................................................................................... 235
Cleaning........................................................................................................................................236
Care ...............................................................................................................................................236
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Parking and storing...................................................................................................237
Safety ............................................................................................................................................237
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Maintenance............................................................................................................... 239
Safety ............................................................................................................................................239
Protection measures....................................................................................................................241
General..........................................................................................................................................241
Maintenance table ........................................................................................................................243
Complete machine .......................................................................................................................250
Bolted connections......................................................................................................................251
PTO drive shaft.............................................................................................................................253
Hydraulics.....................................................................................................................................254
Pick-up/rotor equipment..............................................................................................................257
OptiCut cutting system................................................................................................................261
Bale chamber................................................................................................................................263
Twine binder .................................................................................................................................277
Net binder......................................................................................................................................283
Lubrication systems ....................................................................................................................287
Gearbox.........................................................................................................................................289
Bale transport unit .......................................................................................................................290
Bale wrapper.................................................................................................................................292
Film cutters...................................................................................................................................297

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Satellite..........................................................................................................................................300
Bale turner [+]...............................................................................................................................304
Axle, wheels and tyres.................................................................................................................305
Brakes ...........................................................................................................................................310
Drawbar.........................................................................................................................................313
Sensors .........................................................................................................................................314
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Troubleshooting guide...............................................................................................324
Safety.............................................................................................................................................324
Safety systems .............................................................................................................................325
Malfunctions .................................................................................................................................329
Malfunctions .................................................................................................................................329
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Limited warranty.........................................................................................................367
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Appendix.....................................................................................................................369
Torque value .................................................................................................................................369
Electronic control: Terminal........................................................................................................373
Disposal of the machine..............................................................................................................389
PTO drive shaft.............................................................................................................................390
Diagrams and schemes ...............................................................................................................391
Overviews .....................................................................................................................................393
Specimen of the "Declaration of conformity"............................................................................405

Delivery
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$Delivery
1. Check on delivery
The machine is delivered fully assembled. The machine
must be checked after delivery. Check loose parts
against the following checklist. If any parts of the
machine have not been assembled or are missing,
please contact your dealer.
In case parts are missing or the machine was
damaged during transport, please immediately
contact your dealer, importer, or the
manufacturer.
Check list for parts Quantity
Operation manual 1
Spare part manual 1
Special accessories See delivery note.

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Identification of the machine
$Identification of the machine
1. Front view
2. Rear view

Identification of the machine
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3. Model identification plate
Please write below the type and serial number of the
machine. This information is to be indicated to the dealer
for all spare parts orders.
Type:
Serial no.:
Type:
Serial no.:
Leergewicht / Mass, unloaden
FZ I-Nr./Serial Nr.
Typ / Type
Marke / Brand
Modell / Model
Achslast hinten / Rear axle load
Achslast vorne / Front axle load
Gesamtgewicht / Total adm. mass
Stützlast / Hitch load
Zulässige: / Maximum:
kg
kg
kg
kg
kg
Baujahr / Year of construction
TR 3328
Nuenenseweg 165, 5667 KP Geldrop
The Netherlands
KUHN-GELDROP BV
Mach. ID./ Mach. Nr.
N
°Serie / Nr.identif.
Made by KUHN-GELDROP B.V.
Nuenenseweg 165 , 5667 KP Geldrop, The Netherlands
KUHN S.A.
Z4541880

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Identification of the machine
4. Optional equipment
Tick box corresponding to the equipment fitted on your
machine (factory fitted):
VT50 color terminal including power cable.
CCI 100-ISOBUS color terminal including ECU-power cable.
Net binding system.
Twine and net binding system.
OC14 cutting system with spring knife protection and drop floor.
OC23 cutting system with spring knife protection and drop floor.
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
Wheel chocks (Safety kit).
Automatic chain lubrication system.
Fixed pickup wheels.
Pivoting pickup wheels.
Wheel size 400/60-22.5.
Wheel size 500/45-22.5.
Tandem axles with hydraulic brakes.
Tandem axles with pneumatic brakes.
Standard hitch drawbar eye 40 mm (1 18/32’’).
52 mm (2 2/32’’) drawbar eye (extended length).
Standard 2D wrapping unit.
3D-wrapping unit with pivoting pre-stretchers.
Laced belts.
Endless belts.

Identification of the machine
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Tick box corresponding to the equipment fitted on your
machine (afterwards):
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
Automatic chain lubrication system.

Small bale kit.

Wrapper detachment kit.
Set of spare knives, OC14.
Set of spare knives, OC23.
Dummy knives, OC14.
Dummy knives, OC23.
ECU-power cable for CCI terminal.
power cable for VT50 terminal.
Gear kit pre-stretcher 22/36, approximately 60% pre-stretch.
Bale turner. To deposit the bale on the flat side of the bale.
Transport support for bale turner.
Bale stop arm for bale turner. To prevent the bale from rolling on hilly terrain, used for the flat side.
Hitch ball ø80 mm (3 5/32’’) (SCHARMUELLER type coupling).
Oil flow divider.
Proportional valve.
Low density kit.
Twine wrap kit.
Electric twine run control.
Teardrop plate.
Safety chain for the drawbar.
52 mm (2 2/32’’) drawbar eye (extended length) .

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Safety
$Safety
1. Description of symbols used in this
document
This symbol indicates a potentially hazardous situation
that if not avoided, could result in serious bodily injury.
This symbol is used to identify special instructions or
procedures which, if not followed strictly, could result in
machinery damage.
This symbol is used to communicate technical
information of particular interest.
[+] A plus sign indicates an accessory, which is not included in the standard version.
(x) A number between brackets within the text refers to the number in the drawing(s) belonging to the paragraph.
- A dash indicates operating functions, which have to be performed.
• A dot accompanies each item in a list.

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2. Safety instructions
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Who is allowed to operate the machine?
Only qualified personnel
Only qualified personnel who have been informed about the dangers associated with handling the machine are
permitted to operate, service or repair the machine. This knowledge can be gained by agricultural training,
technical training or intensive instruction.
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General
Safety is your responsibility
Follow the safety regulations. Make sure that you are always in compliance with the safety regulations. Most
accidents can be avoided. Avoid serious or fatal accidents by following the safety instructions.
Use a suitable tractor
Ensure that the tractor meets the listed minimum requirements of the machine. And ensure that the tractor is
capable for safely operating the machine for all your specific conditions.
Prescribed workwear
Do not wear loose, baggy clothing to avoid being caught by the rotating parts. Wear workwear and protective
clothing as prescribed by the trade's mutual indemnity association. Otherwise there is a high risk of serious or
fatal injury.
Oils, lubricants and chemicals
Observe all safety instructions and directions for use for oils, lubricants and chemicals (like paint, cleaning
agents, solvents etc.), as mentioned on the original packaging or chemical cards.
Fire hazard
Ensure the machine is always clean and remove any remaining crop to avoid fire hazards.
Fire extinguisher
Equip the machine with a multipurpose ABC fire extinguisher with a capacity of at least 10 kg (22 lbs). Always
use a fire extinguisher which is approved by the relevant authorities.

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Safety
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Proper operating condition
Ensure that the machine and your tractor are always in a proper operating condition. Always work with a clean
machine, remove any dirt before operation. Observe the information and technical data in the operation manual
of your tractor.
Running in enclosed space
A machine connected and coupled to the tractor may never be used in enclosed spaces. Combustion engine
exhaust fumes are dangerous, and may cause asphyxiation.
Never work on a running machine
Never work on the machine while it is running. Due to its inertia, the PTO continues to rotate after
disengaging. Stay away from of the machine until it has come to a complete stop.
Objects or personnel can be caught, drawn in or crushed.
This is a hazardous situation which, if not avoided, could result in death or serious injuries.
Environment
Binding materials and its packaging can be harmful to animals.
Collect all wasted binding materials and its packaging from the field and dispose of according to the national
waste disposal regulations.
Do not modify the machine
No modifications whatsoever may be made to the machine. Unauthorized modifications can impair safety and
effect the life time of the machine. It even renders the manufacturer's guarantee null and void and frees the
manufacturer from all liability.
Avoid the area to the rear
Remain a safe distance from the rear area. The ejected bale may roll under its own weight and the ejected
speed.This is a hazardous situation which, if not avoided, could result in death or serious injuries.
Deposit the bale on level ground
Always deposit the bale on a flat surface. Never depositbales on a slope. The ejected bale maynot move under
its own weight and the ejection speed.
This is a hazardous situation which, if not avoided, could result in death or serious injuries.
For operating on slopes, the use of a bale turner [+] is recommended.
Bale turner, see page 231.

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Fire hazards when welding
When welding, be careful of any fire or combustion hazards caused by sprayed metal and sparks. Work away
from flammable objects or cover them. Seal off any gaps or chinks. Ensure there is a suitable fire extinguisher
device and check the working premises; check them again at the end of the welding process.
Use the climbing aids
Use the approved and indicated climbing aids on the machine. Only these devices can guarantee sure footing.
There is otherwise a risk of injuries.

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Safety
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Hitching the machine
Increased risk of injury
While hitching the machine to the tractor there is an increased danger of injury. Therefore always:
• Secure the tractor and the machine from rolling away.
• Switch off tractor hydraulics and pneumatics.
• Switch off all electronic systems.
• Switch off the tractor engine.
• Remove the ignition key.
• Mount and secure the PTO drive shaft at the PTO axle.
• Never stay between the tractor and the machine during hitching.
Failure to comply may cause damage to the machine and even life threatening injuries.
PTO
PTO drive shaft
Only use the PTO drive shaft complying with the manufacturer's specification. Other PTO drive shafts with slip
clutches can permit higher torques. Higher torques can damage the machine.
PTO drive shaft operation manual
Regard to the operation manual of the PTO driveshaft manufacturer for correct use of the PTO drive shaft. Obey
the safety instructions mentioned in this manual. Negligence can lead to damage at the PTO drive shaft and to
the machine.
Fix and check PTO drive shaft protection
The rotating PTO drive shaft is secured by a PTO drive shaft protection. Take care that the PTO drive shaft
protection is not damaged. PTO drive shaft protection has to be fixed by chains, to the tractor and the machine.
This prevents the protection cover from rotating. Unprotected PTO drive shafts can cause serious personal
injuries.
PTO speed 540 min-1
The prescribed PTO speed of maximum 540 min-1 may not be exceeded. Higher PTO speeds can damage the
machine.

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Searching for hydraulic oil leaks
Never search for leaks by touching hydraulic hoses, hydraulic hoses and hydraulic connections,
even when your hands are protected with a protective skin cream or oil-resistant gloves.
Due to high pressure and very little holes in case of leakages, the hydraulic oil will go through
protection devices and your skin! Hydraulic oil may come into your bloodstream, which is life
threatening!
Hydraulics
Hydraulic couplings only pressureless
Only connect hydraulic hoses to the tractor hydraulic system if the tractor and machine's hydraulic system is
pressureless. A pressurized hydraulic system can trigger unforeseen movements at the machine. This is a
hazardous situation which, if not avoided, could result in death or serious injuries.
High pressure in the hydraulic system
The hydraulic system is under high pressure. All pipes, hoses, couplings and connecting passageways have to
be checked for leaks and other damages on a regular basis. Only use suitable tools when checking for leaks.
Repair any damage immediately. Escaping oil can cause injuries and burns. Seek medical care immediately
when injuries occur.
Maintenance, see page 239.
Do not use a tractor with a hydraulic oil pressure over 210 bar (3045 psi)
Too high oil pressures will damage the hydraulic system of the machine.

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Safety
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Road transport
Ensure road safety
If you intend to transport the machine on public roads, the machine and the combination of tractor and machine
have to comply to current Road Traffic Act's requirements. This to guarantees your own safety and the safety
of other road users.
For example ensure:
• The license plate, road lighting, warning and protective equipment is properly installed and functioning.
• Compliance with the permissible transport dimensions and weights and axle loads.
• The machine is in compliance with the speed limits:
National and local speed limits.
Speed limits as indicated in the approval of the machine.
Never exceed the maximum design speed, when there are no speed limits indicated in the
approval or when there is no approval.
• The machine is in compliance with the brake requirements of the tractor-machine combination.
Failure to meet the Road Traffic Act's requirements can result in fatal accidents.
Braking system requirements (for USA only):
• Do not tow equipment that does not have brakes:
at speeds over 32 km/h (20 mph); or
that, when fully loaded, has a mass (weight) over 1500 kg (3300lb) and more than 1.5 times the
mass (weight) of the towing unit.
• Do not tow equipment that has brakes:
at speeds over 40 km/h (25mph); or
that, when fully loaded, has a mass (weight) over 4.5 times the mass (weight) of the towing unit.